Ferrule package and method of packaging and loading ferrules

ABSTRACT

A container for packing and shipping stud welding ferrule aligned along a spindle. The container comprises a body having a top, a bottom, opposing side walls and opposing end walls defining a storage space therein. The container further comprises a spindle retainer operatively connected to the body. The spindle retainer has a transverse portion and a longitudinal portion connected to the transverse portion. The transverse portion extends from one of the end walls and toward and into the storage space, while the longitudinal portion extends from the transverse portion and toward the bottom of the body. The transverse portion and the longitudinal portion are sized and shaped to accept and to retain ends of the spindle to contain the spindle within the body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims priority under35 U.S.C. §120 to U.S. Non-Provisional patent application Ser. No.10/900,253 filed Jul. 27, 2004, in the name of the present inventor andentitled “Ferrule Dispenser and Ferrule Package” and is incorporatedherein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE DISCLOSURE

The present invention relates generally to ferrules used in weldingstuds to a work surface. In particular, it relates to a dispenser forplacing the individual ferrules on the work surface, and to packagingand loading ferrules for use with the dispenser.

During structural construction, metal studs are commonly used to improveshear strength in concrete slabs and to provide mounting structure forcomponents of a structural framework. The studs can be connecteddirectly to a bare beam of a structure or can be connected through metaldecking to an underlying beam of a structure. An arc welding process,such as drawn arc welding, is often used to make these connections. Whenusing the drawn arc process, ceramic ferrules are positioned around abase of the stud. The ferrules concentrate weld heat between the studand the work surface and contain the molten pool of melted metal aroundthe base of the stud. This improves quality of the weld and facilitatesformation of a strong weld filet.

Ferrules are usually ordered based on the number of studs to weld. Thepackaging of ferrules usually is conducted remote from the work sitewith the package ferrules delivered to the job site. But the ferrulesare usually packaged based on weight. This can lead to inaccurate ordersbecause a moisture content and a density of each ferrule may vary. Twoboxes of ferrules with similar weights may contain a significantlydifferent numbers of ferrules. The worker is not certain of the precisenumber of ferrules in each package, making planning for a job difficult.

The ferrules are also randomly packaged in boxes prior to shipping. Thiscan damage a substantial number of the ferrules and can possibly leaveonly a fraction of the received ferrules usable. Accordingly, accuratelyordering a desired number of ferrules for a stud welding project can bedifficult.

In response to these drawbacks, ferrule manufactures may use a ferruleretainer to ship the ferrules. Examples are shown in U.S. Pat. Nos.4,600,118 and 5,704,515, the disclosures of which are herebyincorporated by reference. These retainers are capable of holding a setnumber of ferrules in a uniform arrangement and can reduce potentialdamage to the ferrules that may occur during shipping. The retainersusually include a restraining feature at the ends for holding theferrules in place. But having two restraining features can be somewhatburdensome. They require an additional step in making and loading theretainers because at least one of the restraining features must besubsequently added after the ferrules are loaded. They also require anadditional step to access the ferrules at the work site because at leastone of the restraining features must be removed. The retainer on thebottom of the rod is removed by breaking the rod at a predeterminednotch into which the retainer fits, thus allowing the retainer to falloff the rod. The rod is then withdrawn from the ferrules, therebyreleasing the ferrules into the applicator and where they are retainedby the applicator apparatus. Accordingly, there is a need for a simpleand efficient way to ship ferrules to a work site.

In another current method of packing ferrules into a container orpackage, the packer loads individual ferrules along a non-rigidstructure such as a wire tie. After positioning the center boars of theferrules along the non-rigid wire, the packer loops the ends of the wireto maintain the ferrule. The packer then places the wired ferrules intothe package. Since there wire is non-rigid the ferrules tend to innermingle during shipping leading to broken ferrules and tangled ferrulesupon removal from the package at the work site. Further, when the enduser receives the wired ferrules, the user grasps both ends of the wireto lift the ferrules out of the package. Since the wire is non-rigid,the wire requires another worker to assist in removing the ferrules fromthe wire and to load the ferrules onto a dispenser. Requiring more thanworker to assist in loading and unloading ferrules, however, leads toinefficient use of labor time.

At the work site, it is known to have workers place the ferrules atpredetermined locations along the work surface by hand, repeatedlybending over to do so. At the same time, the worker properly orients theferrule. As the ferrules are placed, the worker may drag the box offerrules alongside in order to maintain a constant supply. This,however, is extremely time consuming and physically demanding. So as analternative, the worker may pre-load ferrules into a bolt bag. But thisis also inefficient as the worker must constantly re-fill the bag. Inaddition, the pre-loaded ferrules are subject to damage and stillrequire repeated bending to place.

In response to these inefficiencies, a ferrule applicator may be used toplace the ferrules on the work surface and thereby reduce the physicalstress of repeated bending. Examples of applicators are shown in U.S.Pat. Nos. 4,600,118, 5,704,515, and 6,112,944. Ferrule applicators ofthe prior art are generally capable of holding multiple ferrules in auniform arrangement for repetitious placing on the work surface. In acommon prior art applicator, ball bearings are located around one end ofthe applicator for selectively holding the ferrules or releasing themonto the work surface. In some of these applicators, the ferrules areretained inside the applicator. A spring loaded tubular plunger slidesover an outer surface of the applicator and biases the ball bearings toeither engage the ferrules and retain them inside the applicator orrelease the ferrules and allow them to fall to the work surface. Inother applicators, the ferrules are retained on an outer surface of theapplicator. A spring loaded plunger slides longitudinally inside theapplicator and again biases ball bearings to selectively retain orrelease the ferrules.

But these prior art applicators have drawbacks. For example, the ballbearings may stick or wedge in either a hold position or a releaseposition, resulting in inconsistent operation. In addition, the ballbearings may inadvertently engage a side surface of a ferrule as it isreleased. This can possibly jam the ferrule on (or in) the applicatorand can potentially damage the ferrule so that it is unusable. Moreover,the ball bearings may only move partially into and out of theapplicator. As a result, an irregular ferrule with a slightly largerthan average diameter may not be effectively retained, and an irregularferrule with a slightly smaller than average diameter may not fully passover the bearings.

Accordingly, there is a need for a ferrule retainer that loads quicklyand easily, and that reliably retains ferrules during shipping orstoring. In addition, there is a need for a ferrule retainer that allowseasy access to the retained ferrules at a work site. There is a furtherneed for a ferrule applicator that can reliably place ferrules onto awork surface without jamming and without damaging the ferrules and thatcan consistently operate time after time.

SUMMARY OF THE INVENTION

In one aspect of the invention, a container for packing and shippingstud welding ferrule aligned along a spindle. The container comprises abody having a top, a bottom, opposing side walls and opposing end wallsdefining a storage space therein. The container further comprises aspindle retainer operatively connected to the body. The spindle retainerhas a transverse portion and a longitudinal portion connected to thetransverse portion. The transverse portion extends from one of the endwalls and toward and into the storage space, while the longitudinalportion extends from the transverse portion and toward the bottom of thebody. The transverse portion and the longitudinal portion are sized andshaped to accept and to retain ends of the spindle to contain thespindle within the body.

In another aspect of the invention, a package of stud welding ferrulesgenerally comprises multiple sets of ferrules, each including individualferrules arranged generally one ferrule after another in a stack. Eachferrule is generally annular in shape with an open center and a height.In addition, the package of stud welding ferrules comprises a spindlefor each set of ferrules, received through the ferrules' open centers.The spindle has a length, first and second ends, and a retainer. Theretainer is located at the spindle's first end and retains the ferrulesfrom moving past the retainer and off the first end. The spindle'ssecond end is free of a retainer. The package of ferrules furthercomprises a container receiving the multiple sets of ferrules so thatthe second end of each spindle is separated from the container by adistance that is less than the height of one of the ferrules. In thisposition, the container holds the ferrules from moving off of thespindle's second end.

In still another aspect of the invention, a method for packaging studwelding ferrules generally includes providing a set of stud weldingferrules where each ferrule in the set has a height and a centeropening. The set of ferrules is arranged in a stack on a spindle, whichis received through the center openings of each ferrule in the set.Structure is provided, generally at a first end of the spindle, forretaining the ferrules on the spindle. A second end of the spindle isfree of a similar structure that would prevent the ferrules from movingoff of the spindle's second end. The spindle is then placed in acontainer so that the second end of the spindle is spaced from thecontainer a distance that is less than the height of one of theferrules.

In yet a further aspect of the invention, a method for loading a ferruledispenser with stud welding ferrules that are to be dispensed from theferrule dispenser onto a work surface generally comprises orienting aspindle, which is received through center openings of annular ferrulesthereby arranging the ferrules generally in a stack, so that a first endof the spindle, which has a retainer thereon preventing ferrules frommoving off of the spindle, is located lower than a second end of thespindle. The second end of the spindle is free of any retainer thatwould prevent ferrules from moving off the second end. A second end of arod of the ferrule dispenser is then slid onto the spindle so that thespindle moves into the rod's second end. As this happens, the ferrulesmove from the spindle onto an outer surface of the rod, toward the rod'sfirst end, transferring the ferrules from the spindle to the rod.

Other features will be in part apparent and in part pointed outhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation of a ferrule dispenser loaded with ferrules andbeing used to place the ferrules onto a work surface;

FIG. 2A is an enlarged vertical section of a standard ¾″ WTD typeferrule;

FIG. 2B is an enlarged vertical section of a standard ¾″ F type ferrule;

FIG. 3A is an enlarged perspective of a modified ¾″ WTD type ferrule;

FIG. 3B is a vertical section of the modified ferrule taken on line3B-3B of FIG. 3A;

FIG. 4A is an enlarged perspective of a modified ¾″ F type ferrule;

FIG. 4B is a vertical section of the modified ferrule taken on line4B-4B of FIG. 4A;

FIG. 5 is an elevation of the ferrule dispenser of FIG. 1 with theferrules removed;

FIG. 6 is an enlarged, fragmentary exploded perspective of the ferruledispenser;

FIG. 7A is a fragmentary elevation of the ferrule dispenser withportions of a rod of the dispenser and some of the ferrules broken awayto show internal construction;

FIG. 7B is a fragmentary elevation similar to FIG. 7A, but with theferrule dispenser rotated 90.degree. about longitudinal axis Y-Y of FIG.7A;

FIG. 8A is a perspective of a cam of the ferrule dispenser;

FIG. 8B is the perspective of FIG. 8A rotated 90.degree. aboutlongitudinal axis Y1-Y1 of FIG. 8A;

FIG. 9A is a longitudinal section of the cam taken on line 9A-9A of FIG.8B with two ferrule release pins shown in phantom and engaged by thecam;

FIG. 9B is the section of FIG. 9A rotated 90.degree. about longitudinalaxis Y1-Y1 of FIG. 9A;

FIG. 9C is a section of the cam taken on line 9C-9C of FIG. 8B with twoferrule release pins again shown in phantom and engaged by the cam;

FIG. 10 is a fragmentary longitudinal section of the ferrule dispenser;

FIG. 11A is a fragmentary longitudinal section of the ferrule dispenserloaded with ferrules and in a hold position, just prior to releasing alowermost ferrule onto the work surface;

FIG. 11B is a section similar to FIG. 11A with the ferrule dispenser ina release position, releasing the lowermost ferrule onto the worksurface;

FIG. 11C is a section similar to FIG. 11B with the ferrule dispenser inthe hold position, just after releasing the lowermost ferrule onto thework surface;

FIG. 12 is an exploded elevation of a ferrule dispenser according to asecond embodiment having a rod internally threaded for removablyattaching a dispensing head of the dispenser;

FIG. 13 is an enlarged, fragmentary exploded perspective of the ferruledispenser of FIG. 12;

FIG. 14 is an elevation of a package of ferrules with a portion of acontainer of the package broken away;

FIG. 15 is a fragmentary elevation of a set of ferrules and spindle ofthe package of ferrules of FIG. 14 with a portion of one ferrule brokenaway;

FIG. 16A is a fragmentary elevation of the ferrule dispenser of FIG. 5positioned next to the set of ferrules and spindle of FIG. 15;

FIG. 16B is a fragmentary elevation of the ferrule dispenser, set offerrules, and spindle of FIG. 16A with the ferrule dispenser and spindleoriented for loading ferrules from the spindle onto the dispenser;

FIG. 16C is a fragmentary elevation similar to FIG. 16B with the ferruledispenser loaded with ferrules; and

FIG. 17 is a schematic illustrating movement of the inverted ferruledispenser of FIG. 16C to a position ready for dispensing the ferrulesonto the work surface.

FIG. 18 is a planned view of another package for containing ferrulesconstructed in accordance with and embodying the present disclosure;

FIG. 19 is a side elevational view of a spindle retainer for receivingand retaining a spindle of ferrules.

FIG. 20 is a planned view of a set of ferrules and spindles positionedwithin the package and retained by the spindle retainer.

FIG. 21 is a side elevational view of FIG. 20 illustrating sets offerrules and spindles retained on top of one another and within thepackage;

FIG. 22 is a side elevational view of a removed set of ferrules andspindles placed in a trough;

FIG. 23 is a side elevational of the wire removed from the set offerrules placed in the trough and a ferrule dispenser inserted withinthe set of ferrules.

FIG. 24 is a side elevational view of the ferrule dispenser partiallypositioned within the set of ferrules; and

FIG. 25 is a side elevational view of the dispenser fully positionedwithin the set of ferrules.

Corresponding reference characters indicate corresponding partsthroughout the views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, and particularly to FIG. 1, a ferruledispenser is shown designated generally by reference numeral 1. Theillustrated dispenser 1 is loaded with a number N of stud weldingferrules, each generally designated by reference numeral 3, (in theillustrated embodiment, the ferrule dispenser 1 is loaded withsixty-three ferrules) of which a lowermost ferrule on the dispenser isdesignated generally by reference numeral 3′ and a second subsequentferrule generally by reference numeral 3″. A ferrule dispenser may holdmore or less than sixty-three ferrules without departing from the scopeof the invention. The illustrated dispenser 1 is capable of being usedby a worker (not shown) to dispense the ferrules 3 onto a work surface 4at desired stud locations, one ferrule at a time and one after another.Each dispensed ferrule 3 is properly orientated on the work surface 4for receiving a stud (not shown). The work surface 4 may be a bare beamof a bridge frame or may be a metal deck used to form a floor of abuilding. The metal deck may further be corrugated for strength. It isto be understood that while the illustrated dispenser 1 is described andillustrated as being used with standard ferrules 3, the ferruledispenser may hold different types of ferrules without departing fromthe scope of the invention. Examples of modified ferrules capable ofbeing used with the dispenser 1 will be described hereinafter.

FIGS. 2A and 2B show two types of standard ferrules 3 capable of beingused with the illustrated ferrule dispenser 1. Other types of standardferrules 3 may be used with the dispenser 1 without departing from thescope of the invention. Both types of illustrated ferrules 3 aregenerally annular in shape and have an open center. They include a topcollar 5 and a skirt 7 that together support the stud (not shown) in aperpendicular orientation on the work surface 4. The skirt 7 isgenerally wider than the top collar 5 so that a concave shoulder 8 a isformed around an exterior of the ferrule 3. The ferrule 3 also includesan inner shoulder 8 b around the interior of the ferrule. The skirt 7also includes multiple weld vents 6 along its base. The vents 6 controlair flow to the stud during the welding process, and thereby improve thequality of the weld and maximize the strength of a resulting weld filet.

A standard ¾″ WTD type ferrule is shown in FIG. 2A. This ferrule 3 isgenerally used when welding through a metal floor deck to connect thestud to an underlying beam. It has an overall height H ranging fromabout 0.575 inches to about 0.63 inches and an inner diameter D rangingfrom about 0.78 inches to about 0.84 inches. A standard ¾″ F typeferrule is shown in FIG. 2B. This ferrule 3 is generally used whenwelding directly to a bare beam to connect the stud. It has an overallheight H ranging from about 0.575 inches to about 0.68 inches and aninner diameter D ranging from about 0.76 inches to about 0.80 inches. Itis understood that a dispenser loaded with ferrules having dimensionsoutside the ranges just described does not depart from the scope of theinvention.

FIGS. 3A-4B show two types of modified ferrules capable of being usedwith the illustrated ferrule dispenser 1. The modified ferrules aredesignated generally by reference numeral 3 m, and in the figures aregenerally represented by a modified ¾″ WTD type ferrule (FIGS. 3A and3B) and a modified ¾″ F type ferrule (FIGS. 4A and 4B). Other types ofmodified ferrules 3 m may be used with the dispenser 1 without departingfrom the scope of the invention. The illustrated modified ferrules 3 mare substantially similar to the standard ferrules 3 previouslydescribed, but include a squared-off shoulder 8 c around the exterior ofthe ferrule and have a different overall height H. In one version of themodified ferrules 3 m, each ferrule has an overall height H of about 0.5inches or less. In another version, they each have an overall height Hgreater than or equal to about 0.8. inches. It is to be understood thata dispenser loaded with modified ferrules having dimensions outside theranges just described or loaded with ferrules having differently shapecollars and skirts, including differently shaped shoulders, do notdepart from the scope of the invention.

It is envisioned that during the welding process a modified ferrule grip(not shown) will be used to accommodate the squared-off shoulders of themodified ferrules 3 m and to securely hold the ferrule around a base ofthe stud as a weld is formed. It is further envisioned that the modifiedgrip is substantially similar to grips known in the art, but is shapedto receive the squared-off shoulders 8 c of the modified ferrules. Inparticular, it is envisioned that the modified grip is constructed byrabbeting a gripping surface (i.e., the surface of the grip contactingand holding the ferrule as the weld is formed) of any standard grip sothat the modified grip fits over the squared-off shoulders 8 c of theferrule and locates the ferrule 3 m in proper position to form a weldfilet. This modified grip could also be used with standard ferrules 3.

Referring now to FIGS. 1 and 5, the ferrule dispenser 1 generallycomprises an elongate support (in the illustrated dispenser, theelongate support is a tubular rod 9) and a spring loaded cam system,which is generally designated by reference numeral 13. The cam system 13is mounted on the rod 9 and selectively holds the ferrules 3 on the rod9 or releases them onto the work surface 4. The rod 9 is sized andshaped for passing through the open center of each ferrule 3 and forreceiving multiple ferrules onto an outer surface 11 of the rod 9. Therod 9 includes a longitudinal axis, identified as Y-Y in FIG. 5, adispensing end 15 supporting the cam system 13, and a handle 17. Thedispensing end 15 is chamfered around an outer circumference of the rod9. But a dispenser with a dispensing end squared off (i.e., notchamfered) does not depart from the scope of the invention. The handle17 of the illustrated dispenser is slightly tapered for aiding inloading the ferrules 3 onto the rod 9. It additionally includes lightknurling around the rod's outer surface 11 for helping a worker graspthe dispenser 1. It is understood, however, that a mechanism in whichthe handle is squared off (i.e., not tapered) does not depart from thescope of the invention. Additionally, a mechanism having a handle thatdoes not include knurling or that includes a different grip does notdepart from the scope of the invention. A mechanism having an elongatesupport different from a rod does not depart from the scope of theinvention.

Referring to the fragmentary exploded perspective of the dispenser inFIG. 6, the rod 9 includes a center bore 19 that extends along itslongitudinal axis and defines openings 21 a, 21 b at each end of the rod(only the opening 21 a at the handle 17 is fully visible in FIG. 6). Itis envisioned that the rod 9 is formed of a metal (e.g., steel oraluminum), but it may be constructed of a hard plastic or othersufficiently rigid material capable of retaining the ferrules 3 on therod 9 and placing them on the work surface 4. In addition, even thoughthe illustrated rod 9 is circular in section, it is to be understoodthat a rod having a different cross section does not depart from thescope of the invention. The opening 21 a at the handle 17 along with thecenter bore 19 beneficially enables the rod 9 to receive a spindle 23 offerrules for easily loading the ferrules onto the rod. This uniqueloading system will be described in more detail with reference to FIGS.14-17 hereinafter.

Now referring to FIGS. 5-7B, the spring loaded cam system 13 of theillustrated dispenser generally comprises a cylindrical cam 27, acompression spring 29, and two ferrule release pins 31. The compressionspring 29 is located in the rod 9 between the cam 27 and an abutment pin35. The abutment pin 35 passes through the rod's center bore 19, along adiameter of the rod, and is releasably supported by the rod 9 throughtwo holes 37 located on opposites sides of the rod 9. In this position,the abutment pin 35 is vertically fixed within the rod 9 and provides areaction surface for the spring 29 when the cam 27 moves into and out ofthe rod 9 during operation. While the illustrated embodiment shows thecompression spring 29 biasing the cam 27, it is understood that aferrule dispenser having a different device similarly capable of biasinga cam does not alter the scope of the invention.

Referring now to FIGS. 6-10, the cam 27 is elongated and generallycylindrical, and is disposed generally in the dispensing end 15 of therod along the rod's longitudinal axis. The cam 27 is formed as a solidmass of material, which ideally is the same as the material used to formthe rod 9. However, a hollow cam, a cam formed from a compositematerial, or a cam formed from multiple, individual sections does notdepart from the scope of this invention. Although it is formed as onepiece, for convenience the cam 27 is described herein as having threesections, including a tail 41 at a first longitudinal end, a nose 43 ata second longitudinal end, and a central portion 45 therebetween (FIGS.8A and 8B). The tail 41 is relatively located toward the handle 17 andengages the compression spring 29, while the nose 43 projects out of theopening 21 b at the dispensing end 15 of the rod. The tail 41 includes arelatively thick web 47, two arcuate flanges 49, and an oval-shapedopening 51. The opening 51 extends completely through the web 47 andboth flanges 49, and is intended to receive a keeper pin 53 which issupported by the rod 9 through two holes 55 in the rod in similarfashion to the abutment pin 35 previously described. The keeper pin 53is located between the abutment pin 35 and the rod's dispensing end 15.It slidably retains the cam 27 in the rod 9 and prevents the cam fromcanting relative to the longitudinal axis of the rod during operation.

The central portion 45 of the cam includes two channel-shaped tracks,designated generally by reference numeral 57, extending generallylongitudinally along opposite sides of the cam 27. Each track 57includes a planar cam surface 59 along a floor of the track and twooverhanging lips 63 opposite the cam surface and running parallelthereto. The cam surface 59 and lips 63 of each track are arranged at anangle A1 (FIG. 9A) to the longitudinal axis of the cam 27, so that thecorresponding cam surfaces 59 and pairs of lips 63 each converge towardthe nose 43 of the cam. When the two tracks 57 and their converging camsurfaces 59 and lips 63 are viewed in section from a side, they form a“V” shape (FIGS. 9A and 10). In the illustrated dispenser 1, the angleA1 of the converging surfaces is about 10.degree.-15.degree., but adispenser in which this angle A1 is more or less than10.degree.-15.degree. does not depart from the scope of the invention.In addition, a dispenser with more or less than two ferrule release pinsor with a cam designed to capture more or less than two ferrule releasepins does not depart from the scope of the invention.

Now referring to FIGS. 6, 7A, 7B, 9A, 10, and 11, each captured ferrulerelease pin 31 extends perpendicularly away from the tracks 57 of thecam and passes through a hole 65 in the rod's wall 39. Each hole 65 islocated on an opposite side of the rod 9, and both holes are offsetabout 90.degree. around a circumference of the rod as compared to thelocation of the pairs of holes 37, 55 receiving the abutment pin 35 andthe keeper pin 53. A dispenser in which this offset is greater than orless than 90.degree. does not depart from the scope of the invention. Apath P of each hole 65 (FIG. 10) angles relatively downward, toward thedispensing end 15 of the rod, so that a nonperpendicular angle A3 isformed between the hole's path P and the longitudinal axis of the rod 9.In the illustrated dispenser 1, this angle A3 is about75.degree.-80.degree., but a dispenser having holes for ferrule releasepins making a path that angles more or less than 75.degree.-80.degree.with respect to a longitudinal axis of a rod does not depart from thescope of the invention. When this angle A3 is added to the previouslydescribed acute angle A1 (FIG. 9A) formed between the cam surface 59 andthe cam's longitudinal axis, the two angles form a sum of about90.degree.

As is now apparent and as will be described in greater detailhereinafter, the cam surfaces 59 and overhanging lips 63 of each track57 loosely capture a circular base 61 (FIG. 7B) of a respective one ofthe ferrule release pins 31 within the cam 27 (see FIGS. 9A and 9C whichshows the cam 27 in section and the release pins 31 in broken lines toillustrate their relationship with the cam). This allows the two pins 31to slide within the tracks 57 of the cam along the cam surfaces 59, butrestrains them from moving perpendicular to the cam surfaces. Thus, thebases 61 of the pins slide along the cam surfaces 59 as the cam 27 moveslongitudinally of the rod 9, and the pins 31 slide through the holes 65in the rod. The pins 31 do not, however, move longitudinally of the rod.

A benefit of this ferrule dispenser 1 is that the ferrule release pins31 can be removed from the cam system 13 and rod 9 with relative ease.If one of the pins 31 is damaged during operation, it can be quicklyreplaced. To accomplish this, the worker slides the keeper pin 53 fromits respective holes 55 in the rod 9 using a punch or other similardevice. This allows the cam 27 to freely slide out of the rod 9 throughthe rod's dispensing end 15. The ferrule release pins 31 disengage thecam's tracks 57 and the damaged pin 31 can be manually removed throughthe rod's dispensing end 15. After replacing the damaged pin 31, theworker places the new pin 31 back into its respective hole 65 in therod. The worker then slides the cam 27 back through the dispensing end15 so that its tracks 57 engage and capture the bases 61 of the releasepins. At the same time, the worker ensures the compression spring 29remains positioned above the cam's tail 41. The worker completes therepair by sliding the keeper pin 53 back through its holes 55 in the rodand opening 51 in the cam 27, and the dispenser 1 is again ready foroperation.

FIGS. 11A-11C illustrates operation of the ferrule dispenser 1 forreleasing the lowermost ferrule 3′ onto the work surface 4, whileretaining the ferrules 3 thereabove on the rod 9. FIG. 11A illustratesthe ferrule dispenser 1 in a hold position, prior to releasing thelowermost ferrule 3′. Here, the spring 29 biases the cam's nose 43axially outward of the rod 9, through the dispensing end 15, and holdsit in this position until operation begins. The keeper pin 53 engages atop side 51 a of the oval-shaped opening of the tail and prevents thespring 29 from forcing the cam 27 completely out of the rod 9. Theferrule release pins 31, which are each captured in the cam's tracks 57,are positioned near an upper end of each track, near the cam's tail 41.The pins 31 extend perpendicularly outward from the tracks 57 and passthrough the respective holes 65 in the rod's wall 39. The pins 31 engagethe inner shoulder 8 b of the lowermost ferrule and hold it and theferrules 3 thereabove on the rod 9. The skirt 7 of each retained ferruleengages the top collar 5 of a lower ferrule (with the exception of thelowermost ferrule 3′) and all of the ferrules 3 are retained on the rod9 in proper orientation for placement on the work surface 4.

To release the lowermost ferrule 3′ from the rod 9, the worker positionsthe dispenser 1 with the cam's nose 43 engaging the work surface 4 (seeFIG. 1) and pushes the dispenser 1 downward. As shown in FIG. 11B, thismoves the rod 9 over the cam 27. The keeper pin 53, the abutment pin 35,and the two ferrule release pins 31 each move downward conjointly withthe rod 9. The keeper pin 53 guides the cam 27 as it slides upward intothe rod 9 and prevents it from canting relative to the longitudinal axisof the rod. At the same time, the abutment pin 35 compresses thecompression spring 29 against the cam's tail 41, tending to resist therod's downward motion. The ferrule release pins 31 move downward withinthe cam's tracks 57 and along the tracks' angled cam surfaces 59. As therelease pins 31 move, the overhanging lips 63 of the cam's tracks engagethe base 61 of each respective pin and positively pull the pin 31 inwardrelative to the rod 9. This prevents the pin 31 from sticking in thehold position and jamming ferules 3 on the rod 9. When both pins 31reach the track's bottom longitudinal end near the nose 43 of the cam,their distal ends 73 move substantially into their respective holes 65and disengage the lowermost ferrule 3′. This allows the ferrule 3′ tofall onto the work surface 4 and allows the ferrules 3″, 3 thereabove tomove down relative to the rod 9. This also prevents the pins 31 frominadvertently retaining an irregular ferrule with a slightly smallerthan average diameter on the rod 9.

As the worker raises the dispenser 1 from this release position of FIG.11B, and returns it to the hold position of FIG. 11C, the keeper pin 53,the abutment pin 35, and the two ferrule release pins 31 each moveupward conjointly with the rod 9. The compression spring 29 expands andforces the cam 27 downward, holding the cam's nose 43 against the worksurface 4 as the rod 9 is raised. The ferrules 3 on the rod 9 tend toremain in place relative to the rod 9 as the rod moves so that thelowermost ferrule 3′ slides off the rod's dispensing end 15 and remainson the work surface 4. The downward slope of the release pins 31 helpsto keep the lowermost ferrule 3′ from hanging up on the pins 31 as it isdispensed. The keeper pin 53 slides upward in the tail's opening 51 andagain guides the cam 27 back through the dispensing end 15, preventingit from canting. As the two ferrule release pins 31 move upward with therod 9, they also slide up the cam's tracks 57. So when both ferrulerelease pins 31 reach the upper end of their representative tracks 57,the pins' distal ends 73 are at maximum radial extension and engage theshoulder 8 b of a next subsequent ferrule 3″, retaining it and theremaining ferrules 3 thereabove on the rod 9. At approximately the sametime, the keeper pin 53 engages the top side 51 a of the opening 53 andpulls the nose 43 off the work surface 4. The compression spring 29, nowfully expanded, again holds the cam 27 in position for retaining theremaining ferrules 3 on the rod 9. The process may be repeated torelease the next subsequent ferrule 3″ at a second desired location.

As just described, a benefit of the ferrule dispenser 1 is that the camsurfaces 59 positively pull the release pins 31 inward through thecorresponding holes 65 in the rod, and also positively push the releasepins outward through the corresponding holes. This prevents the pins 31from sticking or jamming in the holes 65 of the rod and ensures that thepins 31 retract fully inward and extend fully outward of the rod 9.Thus, the pins 31 reliably release each ferrule 3, and reliably engageeach subsequent ferrule on the rod 9 and prevent multiple ferrules frominadvertently falling during operation. In addition, the length of eachferrule release pin 31 ensures that when the pins are fully extendedthey will securely retain all ferrules 3 on the rod 9, includingirregular ferrules with slightly larger than average diameters.

As is now apparent, the size of ferrules capable of being used with theferrule dispenser 1 described and illustrated herein depends on thedispenser's dimensions, particularly a general distance of the ferrulerelease pin holes 65 from the dispensing end 15 of the rod. Thedispenser 1 is generally capable of using ferrules 3, 3 m with anoverall height H that is about equal to the general distance from theferrule release pin holes 65 to the dispensing end 15 of the rod (thisgeneral distance will be described in more detail hereinafter). Thedispenser is additionally capable of using ferrules 3, 3 m with anoverall height H that is less than the general distance from the ferrulerelease pin holes 65 to the dispensing end 15 of the rod, but when theferrule height becomes too small in comparison to the hole distance fromthe dispensing end, more than one ferrule 3, 3 m may fall from the rod 9during a single dispensing cycle. It is envisioned that the distancefrom the release pin holes 65 to the dispensing end 15 of the rod, asmeasured by a distance X (FIG. 11B) along the rod's longitudinal axisfrom the nose 43 of the cam (as measured when the cam 27 is fullyretracted and the dispenser 1 is in the release position) to the bottomof either ferrule release pin hole 65, is about 0.7 inches. Accordingly,this dispenser 1 is capable of using any type of ferrule (including thestandard and modified types described herein) having an overall height Hof about 0.7 inches.

It is to be understood, however, that a ferrule dispenser in which adistance X along the rod's longitudinal axis from the nose 43 of the cam(as measured when the cam 27 is fully retracted and the dispenser 1 isin the release position) to the bottom of either ferrule release pinhole 65 is greater than 0.7 inches or is less than 0.7 inches does notdepart from the scope of the invention. For example, the ferruledispenser 1 can be modified so that the distance X along the rod'slongitudinal axis from the nose 43 of the cam (as measured when the cam27 is fully retracted and the dispenser 1 is in the release position) tothe bottom of either ferrule release pin hole 65 is about 0.5 inches orless. This modified dispenser 1 could generally use ferrules 3 with acorresponding overall height H that is about 0.5 inches or less.Accordingly, this dispenser 1 could use the modified ferrules 3 m (FIGS.3A-4B) described herein, or other types of ferrules with a correspondingoverall height H of about 0.5 inches or less. As another example, theferrule dispenser 1 could be modified so that the distance X along therod's longitudinal axis from the nose 43 of the cam (as measured whenthe cam 27 is fully retracted and the dispenser 1 is in the releaseposition) to the bottom of either ferrule release pin hole 65 is about0.8 inches or more. This modified dispenser 1 could generally useferrules with a corresponding overall height H that is about 0.8 inchesor more. It is envisioned that the dimensions of the ferrule dispenser1, including a diameter of the rod 9, could be modified withoutlimitation so that the dispenser could accommodate any type of ferrule.It is understood that such modifications do not alter the scope of theinvention

The ferrule dispenser 1 described and illustrated herein could also bemodified so that, for example, an elongate support (not shown) retainsthe ferrules 3, 3 m inside the support (instead of on a rod's outersurface as described and illustrated herein), as is shown in U.S. Pat.No. 4,600,118 (Martin) and U.S. Pat. No. 5,704,515 (Martin), the entiredisclosures of which have been herein incorporated by reference. But itis to be understood that a cam of this dispenser still positively pullsor pushes ferrule release pins relative to the elongate support toeither hold ferrules inside the support or release them onto a worksurface.

FIGS. 12 and 13 illustrate a second embodiment of the ferrule dispenser,which is designated generally by reference numeral 101 (and broadlyreferred to as a ferrule dispenser tool). Parts of this dispenser 101corresponding to parts of the dispenser 1 previously described andillustrated (FIGS. 1-11C) are designated by the same reference numerals,plus “100.” This dispenser 101 is substantially similar to the dispenser1 previously described and illustrated, but includes a dispensing head115 that is removably attached to an elongate support (the elongatesupport is again shown as a rod 109 in the illustrated embodiment) ofthe dispenser. As shown in FIG. 13, an end 121 c of the rod 109 includesinternal threading 183 and an end 121 d of the dispensing head 115includes corresponding external threading 185. Thus, the dispensing head115 can be attached to the rod 109 by screwing the threaded ends 121 c,121 d together. Similarly, it can be unattached from the rod 109 byunscrewing the two ends 121 c, 121 d. When the dispensing head 115 isattached to the rod 109, the dispenser 101 and its dispensing headoperate identically to the previously described dispenser 1 for placingferrules 3 onto a work surface (not shown). It is understood that adispenser (not shown) having a rod with external threading to receive amating dispensing head or having a rod and dispensing head that attachto one another differently, for example by a pin and hole typeattachment, does not depart from the scope of the invention. Inaddition, it is understood that the a dispenser having an elongatesupport different from a rod, or an elongate support that receivesferrules inside the support does not depart from the scope of theinvention. Thus, it is envisioned that the elongate support of thisembodiment can receive any type of dispensing head known in the art andthat it is not limited to receiving the dispensing head described andillustrated herein.

As with the rod 9 of the dispenser 1 previously described, the rod 109of this embodiment's dispenser includes a center bore 119 that extendsalong its longitudinal axis. In this embodiment, the center bore 119defines the opening 121 c at the threaded end of the rod along with anopening 121 a at a handle 117 of the rod. The opening 121 a at thehandle 117, along with the center bore 119, beneficially enables the rod109 to receive a spindle 23 of ferrules for easily loading the ferrulesonto the rod during the welding process. Loading ferrules onto the rod109 of this dispenser 101 is done identically to loading ferrules ontothe rod 9 of the previously described dispenser 1, and will be describedin more detail with reference to FIGS. 14-17 hereinafter.

Referring now to FIG. 14, a package of standard stud welding ferrules isdesignated generally by reference numeral 75. The package 75 generallycomprises a container (in the illustrated package, the container is abox 77, having a top 77 a, a bottom 77 b, and four sides). The package75 also comprises a number of ferrule sets 25, each with a number N offerrules 3 therein arranged in a uniform stack. The spindle 23 holds theferrules 3 of each set uniformly stacked by passing through the opencenter of each ferrule in the set. In the illustrated embodiment, thepackage 75 includes four sets 25 of ferrules, and each set containssixty-three ferrules. This matches the number of ferrules received onthe loaded ferrule dispenser 1 previously described. A package of studwelding ferrules with a different shaped container does not depart fromthe scope of the invention. A package having a different number offerrule sets or having ferrule sets with greater than or less thansixty-three ferrules therein does not depart from the scope of thisinvention

As shown in FIGS. 14 and 15, the spindle 23 of the package comprises alength of relatively rigid wire 79 having a first end 79 b with a flat,circular retainer 81 and a second end 79 a without such a retainer. Toform the package 75 of the present invention, the set 25 of ferrules isloaded onto the spindle 23 so that the top collar 5 of a first ferrulein the set rests against the retainer 81. The retainer 81 has a diameterthat is at least larger than an inner diameter D (FIGS. 2A-4B) of theferrule's top collar and thereby retains the first ferrule and the otherferrules 3 in the set 25 on the spindle 23. The loaded spindles 23 arethen placed in the box 77 in an upright position, with the first end 79b of each spindle oriented below the second end 79 a and contacting thebottom 77 b of the box. The loaded box 77 is closed, securely holdingthe sets 25 of ferrules and preventing them from moving off the secondend 79 a of the spindle during shipping or storing. In the illustratedpackage 75, the second end 79 a of the spindle is near the top 77 a ofthe container, separated therefrom by a distance that is generally lessthan the height H (FIGS. 2A-4B) of one of the ferrules. But it isunderstood that a package in which a second end of a spindle engages atop of a container or alternatively has a greater spacing than justdescribed does not depart from the scope of the present invention.Preferably, the box 77 is marked so as to indicate which end should beelevated and/or which end should be picked up first. While it isdescribed that the spindle comprises a relatively rigid wire for holdingthe ferrules in stacked arrangement, it is understood that any similarstructure, such as a thin wire or a rigid rod, can be used withoutdeparting from the scope of the invention.

Moving to FIGS. 16A-17, a method of loading one of the sets 25 offerrules onto the ferrule dispenser 1 is illustrated. The worker (notshown) removes one spindle 23 and the set 25 of ferrules retainedthereon from the package 75 and, firmly grasping both ends 79 a, 79 b ofthe spindle, shakes the spindle 23 to uniformly align the ferrules 3along the wire 79 (FIG. 16A). The worker next positions the spindle 23on the ground (not shown) with the first end 79 b lower than the secondend 79 a. The worker then orients the empty ferrule dispenser 1coaxially above the spindle 23 with its dispensing end 15 higher thanits handle 17 (FIG. 16B). It will be understood that although thedispenser 1 and spindle 23 are generally coaxial in loading, and thefirst end 79 a of the spindle is at a lower height than the second end79 b, the dispenser and spindle need not be vertically arranged toachieve loading.

The worker proceeds to load the dispenser 1 by lowering the taperedhandle 17 onto the second end 79 a of the spindle, passing the spindle23 through the handle's opening 21 a and receiving it into the rod'scenter bore 19 (FIG. 16C). The rod 9 passes through the open centers ofeach ferrule 3 of the set 25, moving down the spindle 23 until thehandle 17 contacts the spindle's retainer 81. Finally as shown in theschematic of FIG. 17, to complete the loading process the worker (notshown) turns the inverted ferrule dispenser 1, the spindle 23, and theset 25 of ferrules 180.degree. so that the dispenser is again upright(steps (a)-(c)). Here, the dispenser's dispensing end 15 is near theground and ready for operation. The spindle 23 may be removed from thedispenser 1 (step (d)), leaving the set 25 of ferrules on the rod 9.However, this is not necessary to initiate operation. The ferruledispenser 1 can be used with or without the spindle 23 positioned in therod 9.

Referring now to FIGS. 18-25, a package of ferrules is shown generallyby reference number 82. The package generally comprises a container 84(in the illustrated package the container 84 is a box, having a top 86,a bottom 88, opposing side walls 90 and opposing end walls 92 defining astorage space 93 therein). A package 82 of stud welding ferrules with adifferent shaped container 84 does not depart from the scope of theinvention. The container 84 comprises a variety of materials, such asbut not limited to, paper or cardboard. Further, the container 84 canhave a variety of cross sectional shapes such as square, rectangular orother appropriate configuration. The container 84 can be of any size toaccommodate ferrules, spindles and workers or users of any size.

The package 82 also comprises a number of ferrule sets 94, each with anumber of ferrules “N” therein arranged in a uniformed stack alongspindle 96. The spindle 96 holds the ferrules of each set uniformlystacked by passing through the open center of each ferrule in the set 94as previously described. The spindle 96 of the package 82 comprises alength of relatively rigid wire having a first free 98 end and a secondfree end 100 as compared to the embodiment of FIGS. 14 and 15 whichincludes the circular retainer. As shown in FIGS. 20-23, spindle 96 isfree from any retainer clip. The ferrules are loaded on the spindle 96which is positioned in the center opening or center bores of theferrules. The ferrules are always facing the same direction. Ends 98,100 of the spindle 96 are kept free to allow for spacing for fingerhandling by the packer as will be discussed.

In illustrative embodiment, the package 82 includes four sets offerrules, and each set contains 63 ferrules. This matches the number offerrules received in the loaded ferrule dispenser “0” previouslydescribed. A package 82 having a different number of ferrule sets orhaving ferrule sets with greater than or less than 63 ferrules thereindoes not depart from the scope of the invention.

The container 84 has a length of about two and one-half feet to aboutthree and one-half feet. Optimally, the container 84 has a length ofabout three feet. The container 84 has a height from about four inchesto about seven inches. Optimally, the container 84 has a length of aboutfive and three-quarter inches. The container 84 has a width from aboutfive inches to about seven inches. Optimally, the container 84 has awidth of about six and one-quarter inches.

The package 82 further comprises a spindle retainer 102 disposed withinthe container 84 near each end wall 92. The spindle retainer 102 issized and shaped to accept ends of the spindle 96 and to retain the endsof the spindle 96. The spindle retainer 102 includes a transverseportion 104 and a longitudinal portion 106.

The transverse portion 104 has a proximal end 108, a distal end 110 anda body 112 positioned between the distal end 110 and the proximal end108. The transverse portion 104 planarly extends from one end wall 92 toan opposite end wall 92 of the container 84. In one aspect, thetransverse portion 104 has a rectangular configuration. The transverseportion 104 has a length from about a half inch to about two inches.Optimally, the transverse portion 104 has a length of about one andone-quarter inches. The transverse portion 104 includes a transverseslot 114 defined within the transverse portion 104. The transverse slot114 is spaced from the proximal end 108 and extends toward the distalend 110. The transverse slot 114 has a length, “denoted A”, from about ahalf inch to about one and one-half inches. Optimally, the transverseslot 114 has a length of about one inch. The transverse slot 114 has awidth, “denoted B”, of about one eighth inch to about three quarterinches. Optimally, the transverse slot 114 has a width of aboutone-quarter inch.

The longitudinal portion 106 has a proximal end 116, a distal end 118and a body 120 positioned between the distal end 116 and the proximalend 118. In one aspect, the longitudinal portion 106 has a rectangularconfiguration. The longitudinal portion 106 planarly extends from thetransverse portion 104 toward the bottom 88 of the container 84. Thelongitudinal portion 106 has a length from about four inches to aboutseven inches. Optimally, the longitudinal portion 106 has a length ofabout one and one-quarter inches. The longitudinal portion 106 includesa longitudinal slot 122 defined within the longitudinal portion 106. Thelongitudinal slot 122 operatively connects with the transverse slot 114and extends toward the bottom 88. The longitudinal slot 122 may bespaced from the bottom 88. The longitudinal slot 122 has a length,“denoted C”, from about four inches to about six inches. Optimally, thelongitudinal slot 122 has a length of about five inches. Thelongitudinal slot 122 has a width, “denoted B”, of about one eighth inchto about three quarter inches. Optimally, the longitudinal slot 122 hasa width of about one-quarter inch.

Optimally, the container 84 has four spindle retainers 102 positioned atone end wall 92 and four matching spindle retainers 102 at the oppositeend wall 92. The spindle retainers 102 at one end wall 92 re alignedwith respect to spindle retainers 102 at the other end wall 92. Apackage 82 having a different number of spindle retainers 102 or havingspindle retainers 102 with greater than or less than four spindleretainers 102 does not depart from the scope of the invention. Thedimensions given are representative of an embodiment and not intended tolimit the scope of the disclosure.

For packaging operations, once the spindle 96 is loaded with ferrules,the packer grasps each free end 98, 100 of the spindle 96 with fingersfrom respective hands. The packer then conveniently lifts the loadedspindle 96 and carries the loaded spindle 96 toward the container 84.Since the spindle 96 is rigid, the loaded ferrules remain in alignmentwhile the user transports the loaded spindle 96. The packer then alignsthe free ends 98, 100 of the spindle 96 with a pair of opposingtransverse slots 114 and longitudinal slots of opposing spindle 96retainers 102. The packer inserts or lowers the spindle ends 98, 100into the respective transverse slots 114 and continues to lower thespindle 96 into the longitudinal slots 122. The transverse slots 114 andthe longitudinal slots 122 are sized and shaped to accept and to retainthe spindle ends 98, 100. The packer continues to lower the spindle 96into the longitudinal slots 122 until the ferrules contact the bottom 88of the container 84. The spindle ends 98, 100 extend through thelongitudinal slots 122 and underneath the transverse slots 114 andunderneath the transverse portion 104.

The longitudinal slots 122 are sized and shaped to retain the spindleends 98, 100 to secure the ferrules along the spindle ends 98, 100 toprevent the ferrules from moving off the spindle ends 98, 100 duringshipping or storing. Spacing exists along the spindle ends 98, 100between the longitudinal portions 106 and the outermost loaded ferrulesspaced along the spindle 96. The packer repeats the loading process byplacing successive loaded spindles 96 and associated ferrules into thetransverse slots 114 and longitudinal slots 122 and on top of thelowermost retained spindle 96 until the successive ferrules contact thelower most retained ferrules. Optimally, the packer loads four sets ofloaded spindles 96 within a pair of opposing spindle retainers 102. Thepacker continues to load adjacent spindle retainers 102 until the box isfull. The loaded box is closed, securely holding the set of loadedspindles 96 for shipment.

Upon receiving the shipped package at the work site, the worker opensthe container 84 and inserts fingers around the exposed free ends 98,100 of the spindle 96 via the spacing along the spindle ends 98, 100between the longitudinal portions 106 and the outermost loaded ferrules.The worker lifts the loaded spindle 96 upward along the longitudinalslots 122 and out of the container 84. The longitudinal slots 122 guidethe spindle ends 98, 100 as the worker lifts the loaded spindle 96 outof the container 84. The worker removes the loaded spindle 96 and theset of ferrules retained thereon from the container 84 and, and firmlygrasping both ends 98, 100 of the spindle 96, shakes the spindle 96 touniformly align the ferrules along the spindle 96.

The worker then places the loaded spindle 96 and set of ferrulesretained thereon into a receiver 124 such as a v-shaped trough. Thereceiver 124 may be positioned on a work table or mobile cart. Thereceiver 124 has an open end 126, a closed end 128 and a channel body130 disposed between the open end 126 and the closed end 128. In oneaspect, the closed end 128 comprises a vertical wall. The workerorientates the spindle 96 into the receiver 124 such that the teethedends of the ferrules face the open end 126 of the receiver 124. Theworker aligns the ferrules by pushing the ferrules toward the closed end128 such that the last ferrule contacts the closed end 128 to compactthe ferrules against each other. Since the spindle 96 is free from anyclipper retainer, the worker simply grasps the spindle end 98 near theopen end of 126 the receiver 124 and pulls the spindle 96 out of thecenter bores of the ferrules wherein the receiver 124 maintains the nowloose ferrules in alignment.

The worker proceeds to load the dispenser “D” by passing the handle ofthe dispenser through the open centers of each ferrule of the set movingdown the ferrules until the handle contacts the closed end 128 of thereceiver 124. To complete the loading process, the worker lifts theferrule “D” and set of ferrules aligned thereon so that the dispensingend of the dispenser is again upright. Here, the dispensing end is nearthe ground and ready for operation as previously described. Asdescribed, a single worker can remove the loaded spindle 96 from thecontainer 84; placed the loaded spindle 96 in the receiver 124; removethe spindle 96 from the ferrules and insert the dispenser “D” into theferrules contained by the receiver 124.

When introducing elements of the present invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Moreover, the use of “up” and “down” and “top” and “bottom”and “end” and “side” and variations thereof is made for convenience, butdoes not require any particular orientation of the components.

As various changes could be made in the above without departing from thescope of the invention, it is intended that all matter contained in theabove description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

The invention claimed is:
 1. A method of packaging stud welding ferrulescomprising: providing a set of stud welding ferrules, each ferrulehaving a height and a center opening; arranging the set of ferrules in astack with a rigid spindle received through the center openings of theferrules; providing structure generally at a first end of the rigidspindle for retaining ferrules on the rigid spindle and leaving a secondend of the rigid spindle free of structure which would prevent ferrulesfrom moving off of the second end of the rigid spindle; and placing therigid spindle in a spindle retainer such that the first end and thesecond end are configured to be inserted within respective slots of thespindle retainer and the first end and the second end of the rigidspindle are removably engaged to the spindle retainer and is spaced fromthe spindle retainer a distance less than the height of one of theferrules.
 2. A method of loading a ferrule dispenser with stud weldingferrules to be dispensed from the ferrule dispenser onto a work surface,the method comprising: orienting a spindle received through centeropenings of annular ferrules separately arranged generally in a stack sothat a first end of the spindle having a retainer thereon configured toprevent ferrules from moving past the retainer off of the first end ofthe spindle, the first end of the spindle is located below a second endof the spindle free of any retainer which would prevent ferrules frommoving off of the spindle at the second end thereof; orienting a rod sothat a first rod end thereof is located higher than a second rod end;sliding the second rod end of the ferrule dispenser around the spindlesuch that the spindle is received into the rod at the second rod endthereof, the ferrules moving from the spindle onto an outer surface ofthe rod toward the first rod end as the spindle is inserted into the rodthereby transferring the ferrules from the spindle to the rod; andre-orienting the rod so that the first rod end thereof is located lowerthan the second rod end.
 3. A method as set forth in claim 2 furthercomprising the step of sliding the spindle out of the rod so that theferrules remain on the outer surface of the rod.
 4. A method of loadinga ferrule dispenser with stud welding ferrules to be dispensed from theferrule dispenser onto a work surface, the method comprising: providinga rigid spindle having a first free end and a second free end; orientingat least the second free end of the rigid spindle received throughcenter openings of annular ferrules separately arranged generally in astack aligned along the rigid spindle; placing the rigid spindle andaligned ferrules into a receiver; sliding the rigid spindle out of thealigned ferrules; retaining the free, aligned ferrules in the receiver;and sliding a handle of a ferrule dispenser into the ferrules alignedwithin the receiver, the ferrules moving from the receiver onto an outersurface of the ferrule dispenser toward a first end of the ferruledispenser as the ferrule dispenser is inserted into the ferrulestransferring the ferrules from the receiver to the ferrule dispenser.